cb, cc, cg service manual - 6422

30
WINSTON PRODUCTS COMPANY 2345 CARTON DRIVE . LOUISVILLE, KENTUCKY . 40299 . (800)234-5CTN . FAX (502)491 - 1814 CVAP VAPOR OVEN CB & CG PROCESS CONTROL MODELS (.04 Software) MANUAL REORDER: LIT 6422 REV 0/5-89 SERVICE MANUAL FOR MODEL NOS. CG15P11SE CB21P11SE CB53P11SE The procedures contained in this manual involve accessing bare electrical terminals and exposes one to voltages capable of producing serious injury or death. Any person attempting diagnosis and/or repair involving removal of panels and/or exposure to live electrical components must be trained or experienced in such service procedures. Disconnect electrical service while performing the procedures listed in this manual. DANGER

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Page 1: CB, CC, CG Service Manual - 6422

WINSTONPRODUCTS COMPANY

2345 CARTON DRIVE . LOUISVILLE, KENTUCKY . 40299 . (800)234-5CTN . FAX (502)491 - 1814

CVAP VAPOROVEN

CB & CGPROCESS CONTROL MODELS

(.04 Software)MANUAL REORDER: LIT 6422 REV 0/5-89

SERVICE MANUAL

FOR MODEL NOS.CG15P11SECB21P11SECB53P11SE

The procedures contained in this manual involve accessing bare electricalterminals and exposes one to voltages capable of producing serious injury ordeath. Any person attempting diagnosis and/or repair involving removal ofpanels and/or exposure to live electrical components must be trained orexperienced in such service procedures. Disconnect electrical service whileperforming the procedures listed in this manual.

DANGER

Page 2: CB, CC, CG Service Manual - 6422

INTRODUCTION

This Service Manual is to be used for the following model CVAP VAPOR OVENS:CB21P11SE, CG15P11SE AND CB53P11SE.

SAFETYKnowledge of the proper installation, operation and maintenance procedures is an important step to insuresafe operation of any equipment. The instructions in this manual are meant as guidelines for proper serviceof the CVAP VAPOR OVEN. In accordance with generally accepted product safety labeling guidelinesfor potential hazards, the following two signal words are used throughout this handbook where applicable.

DANGER — — Used to indicate the presence of a hazard which could cause severe personal injury, death,or substantial property damage if warning is ignored.

CAUTION — — Used to indicate the presence of a hazard which could cause minor personal injury orproperty damage if warning is ignored.

RECOMMENDED TOOLSNut driver 5/16”Nut driver 7/16”Nut driver 3/8”Nut driver 5/8”Nut driver 11/32”Flat blade screwdriver 3/16”Flat blade screwdriver 1/4”Phillips screwdriver #2Calibration screwdriverPliers, standardOpen end wrench 1/2”Open end wrench 9/16”Open end wrench 3/8”Open end wrench 1”Putty knifeNeedle nose pliersAllen wrench 5/64”Terminal crimpersWire strippersWire cuttersSharp knifeNylon string - 10 feet

05/15/89 PAGE1 LIT6422.1

DANGER: THE PROCEDURES CONTAINED IN THIS MANUAL INVOLVE ACCESSINGBARE ELECTRICAL TERMINALS AND EXPOSES ONE TO VOLTAGES CAPABLE OFPRODUCING SERIOUS INJURY OR DEATH. ANY PERSON ATTEMPTING DIAGNOSISAND/OR REPAIR INVOLVING REMOVAL OF PANELS AND/OR EXPOSURE TO LIVEELECTRICAL COMPONENTS MUST BE TRAINED OR EXPERIENCED IN SUCHSERVICE PROCEDURES. DISCONNECT ELECTRICAL SERVICE WHILE PERFORMINGTHE PROCEDURES LISTED IN THIS MANUAL.

Page 3: CB, CC, CG Service Manual - 6422

TABLE OF CONTENTSPAGE

INTRODUCTION………………………………………………………………………………. 1

TABLE OF CONTENTS…………………………………………………………………………2

REPLACE AIR THERMOCOUPLE PROBE ASSEMBLY…………………………………..3

REPLACE EVAPORATOR THERMOCOUPLE……………………………………………...4

REPLACE FLOAT and ARM HOLDER ASSEMBLY………………………………………. 5

REPLACE FLOAT and ARM ASSEMBLY…………………………………………………….6

REPLACE FLOAT/NEEDLE VALVE and SEAT…………………………………………….6

REPLACE DOOR LATCH and CATCH………………………………………………………..7

REPLACE POWER CORD………………………………………………………………………7

REPLACE DOOR HINGE………………………………………………………………………..8

REPLACE DOOR GASKET………………………………………………………………………8

DOOR GASKET ADJUSTMENT………………………………………………………………9

REPLACE CASTERS……………………………………………………………………………10

REPLACE EVAPORATOR HEATER…………………………………………………………10

REPLACE AIR HEATER………………………………………………………………………11

REPLACE POWER SWITCH…………………………………………………………………….12

REPLACE START SWITCH…………………………………………………………………….12

REPLACE CIRCUIT BOARD …………………………………………………………………13

REPLACE TRANSFORMER …………………………………………………………………14

REPLACE POWER BOARD ………………………………………………………………… 14

REPLACE KEY PAD …………………………………………………………………………15

REPLACE BUZZER……………………………………………………………………………15

REPLACE MEAT PROBE…………………………………………………………………… 16

PARTS IDENTIFICATION……………………………………………………………17 - 24

SCHEMATIC ……………………………………………………………………………………25

TROUBLESHOOTING………………………………………………………………………26, 27

EXPLANATION OF ERROR MESSAGES ER-1 THRU ER-6 ……………………………27

ZAP WARRANTY AGREEMENT……………………………………………………………28

PARTS ORDERING INFORMATION ……………………………………………………… 29

05/15/89 PAGE 2 L IT 6422.2

Page 4: CB, CC, CG Service Manual - 6422

REPLACE AIR THERMOCOUPLE PROBE ASSEMBLY

Tools: Phillips screwdriver #2; Flat blade screwdriver 1/4”; Nut driver 3/8”; knife.

Component: AIR THERMOCOUPLE PROBE ASSEMBLY

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top. Savescrews for reuse.

3. Loosen and remove the two screws holding power board bracket to escutcheon. Savescrews for reuse.

4. Carefully lay power board bracket back from escutcheon.

5. Disconnect faulty air thermocouple #1 or #2, whichever applicable, from circuit board.

6. Remove the two screws holding the access plate to side of cabinet, (MI thermocoupleprobe assembly is behind bottom access plate and #2 assembly behind top). Save screwsfor reuse.

7. Cut a hole through the insulation at the faulty air thermocouple access hole.

8. Loosen and remove the two hex nuts holding the probe bracket to cabinet side. Save nutsfor reuse. (See picture at right.)

9. Securely tie a thin cord, (preferably nylon) to the circuit board end of the thermocouple wire.

10. Remove the faulty thermocouple probe and bracket from cabinet side.

11. Carefully pull thermocouple wire down through cabinet side. When wire is completely pulled through, remove cord from old thermocouple leaving cord in place.

12. Remove defective probe assembly from bracket.

13. Insert new probe assembly into bracket and mount to cabinet side.

14. Securely tie cord to new thermocouple wire. From the top of the unit, carefully pull thethermocouple wire up through cabinet side. When wire is completely pulled throughremove cord and attach thermocouple wires to circuit board.

05/15/89 PAGE 3 LIT 6422.3

15. Reassemble cabinet and put unit back into service.

Page 5: CB, CC, CG Service Manual - 6422

REPLACE EVAPORATOR THERMOCOUPLE

Tools: Phillips screwdriver #2; Flat blade screwdriver 1/4”; Nut driver 5/16” and 7/16”.

Component: EVAPORATOR THERMOCOUPLE

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top.Save screws for reuse.

3. Loosen and remove the two screws holding the power board bracket to escutcheon.Save screws for reuse.

4. Carefully lay power board bracket back from escutcheon.

5. Disconnect faulty evaporator thermocouple #3 from circuit board.

6. Lay cabinet on side; pad floor to protect cabinet side from scratches. Use care toprevent damage to power cord.

7. Loosen and remove the six screws holding galvanized oven bottom. Remove bottomand insulation adjacent to it. Save all screws for reuse.

8. Loosen and remove hex nut holding thermocouple ring to tank stud. Save hex nut forreuse.

9. Securely tie a nylon cord to the circuit board end of the thermocouple wire.

10. Remove thermocouple ring from tank stud and carefully pull wire down throughcabinet side. When wire is pulled clear, untie nylon cord but do not remove cord fromcabinet.

11. Attach new thermocouple ring to tank stud.

12. Securely tie nylon cord to the circuit board end of the new evaporator thermocouple.

13. From the top of the unit, carefully pull the thermocouple wire up through cabinet side.When wire is completely pulled through, remove nylon cord and attach thermocouplewires to circuit board.

14. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 4 LIT6422.4

Page 6: CB, CC, CG Service Manual - 6422

REPLACE FLOAT AND ARM HOLDER ASSEMBLY

Tools: Open end wrench 9/16”, Open end wrench 1/2’, Phillips screwdriver #2, Nut driver5/16”, Putty knife.

Component: FLOAT AND ARM HOLDER ASSEMBLY

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply, drainand allow to cool.

2. Remove shelf racks

3. Loosen and remove the two screws holding the float guard to the cabinet base. Save screwsfor reuse.

4. From inside cabinet, carefully pull float assembly upwards exposing tubing. (See picture below)

5. Remove brass hex nut from bushing, thus freeing tubing from float assembly. Save tubingand brass nut for reuse.

6. Install tubing to new float assembly.

7. Mount float assembly to cabinet base.

8. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 5 LIT 6422.5

Page 7: CB, CC, CG Service Manual - 6422

REPLACE FLOAT AND ARM ASSEMBLY

Tools: Phillips screwdriver #2; Needle nose pliers.

Component:FLOAT AND ARM ASSEMBLY

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Remove shelf racks and save for reuse.

3. Loosen the wing nut(s) holding float guard to float assembly. (Older modelCVAPs have two Phillip screws securing float guard to float assembly).

4. Using needle nose pliers, push then pull float pin from the arm holding assemblyfreeing the float and arm.

5. Install new float and arm assembly.

6. Reassemble cabinet and put unit back into service.

REPLACE FLOAT/NEEDLE VALVE AND SEAT

Tools:Phillips screwdriver #2; Needle nose pliers.

Component:NEEDLE VALVE AND SEAT

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect watersupply, drain and allow to cool.

2. Remove shelf racks and save for reuse.

3. Loosen the wing nut(s) holding the float guard to the float assembly. (Older modelCVAPs have two Phillip screws securing float guard to float assembly).

4. Using needle nose pliers, push then pull the float pin from the arm holder assemblythus freeing the float and arm assembly.

5. Remove needle valve and replace rubber seat.

6. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 6 LIT 6422.6

Page 8: CB, CC, CG Service Manual - 6422

REPLACE DOOR LATCH AND CATCH

Tools: Flat blade screwdriver 1/4”; Phillips screwdriver #2; Allen wrench 5/64”.

Component: DOOR LATCH AND CATCH

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the three screws holding latch to door.

3. Loosen and remove the three screws holding catch to cabinet.

4. Install new latch and catch. Prior to final tightening of the catch, insure for properalignment as per the latch position. See DOOR GASKET ADJUSTMENT and followprior to putting unit back into service.

REPLACE POWER CORD

Tools: Flat blade screwdriver 1/4”; Phillips screwdriver #2; Nut driver 5/16”; Standardpliers.

Component: POWER CORD

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top.Save screws for reuse.

3. Loosen and remove wire nuts from power cord inside terminal box. Save wire nuts forreuse.

4. Loosen and remove the screw holding ground wire in terminal box. Save screw forreuse.

5. Compress and remove power cord strain relief and remove cord.

6. Install new power cord, connect ground wire, attach wire nuts and reinsert strain relief.

7. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 7 LIT 6422.7

Page 9: CB, CC, CG Service Manual - 6422

REPLACE DOOR HINGES

Tools: Flat blade screwdriver 1/4”; Phillips screwdriver #2; Nut driver 3/8”.

Component: DOOR HINGE

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Remove the two hinge covers from door hinges. Save for reuse.

3. Remove the six hinge screws holding the door to cabinet side. CAUTION: Use care toprevent door from falling while removing these screws. Remove door from cabinet. Savescrews for reuse.

4. Loosen and remove the ten screws holding the inner door panel to outer door panel. Saveall screws for reuse.

5. Separate the two panels and remove insulation. Save insulation for reuse.

6. Loosen and remove the six screws holding the hinges and spacers to outer door panel.Save screws and spacers for reuse.

7. Install new hinges on door. Perform DOOR GASKET ADJUSTMENT prior to puttingcabinet back into service.

REPLACE DOOR GASKET

Tools: Phillips screwdriver #2; Flat blade screwdriver 1/4”, Allen wrench 5/64”.

Component: DOOR GASKET

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the 10 screws holding the inner and outer door panels together.Save screws for reuse.

3. Remove the old gasket by sliding it out of the groove between the inside door paneland the mounting bracket. Install new gasket, perform DOOR GASKET ADJUSTMENT,reassemble cabinet and put unit back into service.

05/15/89 PAGE 8 LIT 6422.8

Page 10: CB, CC, CG Service Manual - 6422

DOOR GASKET ADJUSTMENT

Tools: Allen wrench 5/64”; Phillips screwdriver #2; Flat blade screwdriver 1/4”.

Door adjustment should be such that the gasket will seize a 1” wide strip of bond paperthrough-out the entire length of the gasket while door is closed.

ADJUST DOOR CATCH

1. Adjust the seal of the door by adjusting the door catch. Loosen the allen screw, butdo not take it completely out.

2. Once loosened enough, turn the catch one complete turn clockwise to tighten seal, orone turn counterclockwise to loosen. Tighten allen screw to where end is receding somewhat from end of catch.

ADJUST DOOR HINGES

1. Remove the two hinge covers and save for reuse.

2. Loosen but do not remove the six hinge screws on door.

3. Move the door inward toward cabinet interior for tighter seal, or outward for looser seal.

4. While holding door in position, tighten hinge screws. Replace hinge covers and put unit back into service.

05/15/89 PAGE 9 LIT 6422.9

Page 11: CB, CC, CG Service Manual - 6422

REPLACE CASTERTools:Flat blade screwdriver #2; Channel lock pliers.

Component: CASTER

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Pad floor and lay cabinet on side.

3. Using screwdriver, pry caster out from leg.

4. Install new caster, reassemble cabinet and put unit back into service.

REPLACE EVAPORATOR HEATERTools:Nut driver 5/16”, 7/16”; Standard pliers; Open end wrench 3/8”.

Component:EVAPORATOR HEATER

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Pad floor and lay cabinet on side.

3. Loosen and remove the six screws holding galvanized oven bottom and remove bottom.Save screws for reuse.

4. Loosen and remove the sixteen nuts holding the three heater shields in place. Removeshields and drain pipe, now allowing heater to be removed. Save nuts, shields and pipefor reuse.

5. Using great care, hold the heater end behind the wire terminal, loosen and remove thehex nut, (both heater ends). (See picture below.)

6. Install the new evaporator heater making sure the terminal connections are tight.

7. Reassemble cabinet and put unit hack into service.

05/ 15/89 PAGE 10 LIT 6422.10

Page 12: CB, CC, CG Service Manual - 6422

REPLACE AIR HEATER

Tools: Nut driver 5/16”; Wire cutters; Open end wrench 3/8” and 9/16”.

Component: AIR HEATER

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Remove shelf racks and save for reuse.

3. Loosen and remove the two hex nuts from the heater holder if applicable, (older modelshave heater shields versus heater holders). Remove the heater holder or shield fromheater. Save hex nuts, holder or shield for reuse.

4. Pad floor and lay cabinet on side.

5. Loosen and remove the six screws holding the galvanized oven bottom and removebottom. Save screws for reuse.

6. Using great care, hold the heater end behind the wire terminal, loosen and remove thehex nut, (both heater ends). (Refer to picture on page 10.)

7. Loosen and remove the two compression nuts around each end of the heater bushings.Pull the heater outward to expose the ferrule around each heater end. It will be necessaryto pinch the ferrules several times with cutters to remove them from the heaters. Once

this is accomplished the heater can be removed.

8. For models having air heaters coming out of the top of the evaporator tank, use thefollowing procedure: When installing a new heater, the top loop should be 1-3/4” abovethe tank top. This should allow 1/4” clearance between the heater and the bottom of theshelf racks.

9. Install new air heater, making sure terminal connections are tight.

10. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 11 LIT 6422.11

Page 13: CB, CC, CG Service Manual - 6422

REPLACE POWER SWITCH

Tools: Nut driver 5/8”, Phillips screwdriver #2.

Component:POWER SWITCH

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top. Savescrews for reuse.

3. Loosen and remove the hex nut and switch guard holding the power switch to escutcheon.Save nut and switch guard for reuse.

4. Move switch to one side without disconnecting wiring. Transfer the wiring to the newpower switch from the respective left to right terminals of the old switch.

5. Reassemble cabinet and put unit back into service.

REPLACE START SWITCH

Tools:Nut driver 11/31”; Nut driver 5/16”; Phillips screwdriver #2; Flatblade screwdriver 3/16”.

Component:START SWITCH

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top.Save screws for reuse.

3. Loosen and remove the two screws holding the power board bracket to escutcheon.Save screws for reuse.

4. Loosen and remove the two nuts holding the start switch to bracket. Save nuts forreuse.

5. Transfer the wiring to new start switch from respective left to right terminals of theold start switch.

6. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 12 LIT 6422.12

Page 14: CB, CC, CG Service Manual - 6422

REPLACE CIRCUIT BOARD

Tools: Nut Driver 11/32”; Phillips screwdriver #2; Flat blade screwdriver 3/16”.

Component:CIRCUIT BOARD

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect watersupply, drain and allow to cool.

2. Loosen and remove the six screws holding top to side members and remove top.Save screws for reuse.

3. Loosen and remove the two screws holding the power board bracket to theescutcheon. Save screws for reuse.

4. Carefully lay power board bracket back from escutcheon.

5. Disconnect wiring harness plug from circuit board.

6. Disconnect thermocouples from circuit board.7. Loosen and remove the four nuts holding the circuit board mounting bracket to the

escutcheon.

8. Remove circuit board and mounting bracket from escutcheon.

9. Install new circuit board and mounting bracket on escutcheon.

10. Attach thermocouple wires observing red and yellow terminal connections.

11. Reassemble cabinet and put unit back into service.

05/15/89 PAGE13 LIT 6422.13

Page 15: CB, CC, CG Service Manual - 6422

REPLACE TRANSFORMER

Tools:Phillips screwdriver #2; Flat blade screwdriver 1/4”.

Component:TRANSFORMER

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect watersupply, drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and removetop. Save screws for reuse.

3. Loosen and remove the two screws holding the power board bracket toescutcheon. Save screws for reuse.

4. Carefully lay power board bracket back from escutcheon.

5. Disconnect the two wiring harness plugs from power board bracket.

6. Loosen and remove the two screws holding transformer to bracket. Save screwsfor reuse.

7. Mount new transformer and attach wiring harness plugs.

8. Reassemble cabinet and put unit back into service.

REPLACE POWER BOARD

Tools:Flat blade screwdriver 1/4”; Phillips screwdriver #2

Component:POWER BOARD

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect watersupply, drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and removetop. Save screws for reuse.

3. Loosen and remove the four screws holding the power board to bracket.

4. Move power board to side and mount new board to bracket.

5. IMPORTANT: Transfer wiring to new power board from the respective top tobottom terminals of the old power board.

6. Reassemble cabinet and put unit back into service

05/15/89 PAGE 14 LIT 6422.14

Page 16: CB, CC, CG Service Manual - 6422

REPLACE KEY PAD

Tools: Nut Driver 11/32”, Phillips screwdriver #2.

Component: KEY PAD

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top.Savescrews for reuse.

3. Loosen and remove the two screws holding power board bracket to escutcheon. Savescrews for reuse.

4. Carefully lay power board bracket back from escutcheon.

5. Loosen and remove the four nuts holding the circuit board mounting bracket to escutcheon.

6. Remove circuit board mounting bracket from escutcheon and disconnect key pad ribbon.

7. Loosen and remove the two nuts holding key pad bracket to escutcheon and remove oldkey pad.

8. Install new key pad being careful to properly position rubber gasket under key pad.

9. Reassemble cabinet and put unit back into service.

REPLACE BUZZER

Tools: Phillips screwdriver #2; Flatblade screwdriver 3/16”.

Component:BUZZER

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply,drain and allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top. Savescrews for reuse.

3. Loosen and remove the two screws holding the power board bracket to escutcheon.Save screws for reuse.

4. Carefully lay power board bracket back from escutcheon.

5. Loosen and remove the two screws holding the buzzer bracket to power board bracket.Save screws for reuse.

6. Loosen and remove buzzer collar from bracket and replace on old bracket.

7. Loosen but do not remove screws holding wires to buzzer. Transfer wires to newbuzzer making sure black wire attaches to positive terminal and white to negative.

8. Reassemble cabinet and put back into service.

05/15/89 PAGE 15 LIT 642215

Page 17: CB, CC, CG Service Manual - 6422

REPLACE MEAT PROBE

Tools: Phillips screwdriver #2; Flatblade screwdriver 1/4”; Side cutters; Needle nose pliers;Terminal crimpers.

Component: MEAT PROBE

Procedure:

1. Turn off electrical power, disconnect electrical power supply, disconnect water supply, drainand allow to cool.

2. Loosen and remove the six screws holding the top to side members and remove top. Saveall screws for reuse.

3. Loosen and remove the screw holding the probe grounding cable to the cabinet chassis.Save screw for reuse.

4. Remove the two screws holding power board bracket from escutcheon and carefully laybracket back.

5. Remove the #4 thermocouple wires from circuit board.

6. Remove terminal end from grounding cable and using needle nose pliers, thread cable loosefrom the metal “L” tube.

7. Remove the metal “L” tube by pulling up with a twisting motion. Pull tube off of thermocouplewires. Save tube for reuse.

8. Remove probe from cabinet inner top by pulling downward.

9. Install new probe, starting with threading thermocouple wires and grounding cable upthrough inner top. Use EXTREME CAUTION not to severely twist rubber tube whileinserting through inner top. Install metal “L” by first threading metal grounding cable throughholes in ring on tube. NOTE: The cable must be pulled up tight enough that the red andyellow cover shield on the thermocouple wires is showing past the open end of the tube.

10. Attach thermocouple wires to circuit board.

11. Reassemble cabinet and put unit back into service.

05/15/89 PAGE 16 LIT 6422.16

Page 18: CB, CC, CG Service Manual - 6422

PARTS IDENTIFICATIONKIT CONTENTPHOTO

REFNUMBER

PARTS DESCRIPTION ORDERNUMBER QTY DESC.

1 Indicator Lamp PS1103/3 3 Lamps2 Switch, On, Off, ( CVAP, FRY, S/T ) PS1529 1 Switch3 Push Button, Black PS1652 1 Button4 Latch & Catch-Door PS1256 1

1LatchCatch

5 Drip Cup PS1423 11

Drip CupBaffle

6 Caster Asm 2” Non Lock (CG)-Rear 2” Lock (CG)-Front 4” Lock (CB)-Front 4” Non Lock (CB)-Rear

PS1480/2PS1481/2PS1482/2PS1483/2

2 Caster Asm

7 Key Pad(CVAP-P.04) PS1651 1 Key Pad Asm8 Clamp-Instruction Envelope PS1638 1

11

ClampScrewEnvelope

9 Door Asm

Model CB21Model CB53 (Top)Model CB53 (Bottom)Model CG15

PS1471PS1472PS1477PS1479

121

Door AsmHingesLatch

10 Hinge Kit Door PS1255/2 22

HingesHinge Covers

11 Fitting, Water Inlet (Plastic) PS1683 11

FittingO-Ring

12 Shelf Rack, Flue Model CB21Model CB53 (Top)Model CB53 (Bottom)Model CG15

PS1650PS1646PS1645PS1656

1 Shelf RackComplete

13 Scr 10-32 X 1/2-Catch PS1239/6 6 Screws14 Cover, Evap CPC/CGPC/CD PS1674 1 Cover, Evap

05/15/89 PAGE 17 LIT 6422.17

Page 19: CB, CC, CG Service Manual - 6422

PARTS IDENTIFICATIONContinued

KIT CONTENTPHOTOREF

NUMBERPARTS DESCRIPTION ORDER

NUMBER QTY DESC.

15 Gasket – DoorModel CB21Model CB53 (Top)Model CB53 (Bottom)Model CG15

PS1441PS1442PS1446PS1444

1 Gasket

16 Scr 10-32X1-1/2 - latch PS1238/6 1 Screws17 Float/Valve/Cover Kit PS1426 1

1111221

1

CoverBailFloat ArmFloat BulbO-RingWashersScrewsNeedle Valve& SeatHolder, Arm

18 Heater – Air/Flu Type 120V, 720W

PS1641 122

22

HeaterFerrulesCompressionNutsWashersNuts

19 Probe – Meat (PC CVAP) PS1422 1 Meat Probe20 Bracket, Probe Holder PS1675 1 Bracket, Probe

21 Drain Pipe (CB, CG) PS1629 1 Drain Pipe22 Thermocouple, Water

(CVAP D, P.04)PS1642 1 Thermocouple

Asm.23 Heater, Water 120V, 720W PS1434 1

22

22

HeaterFerrulesCompressionNutsWashersNuts

24 Wire Harness (.03, .04) PS1672 1 WireHarness

25 Transformer (CVAP-D, P.04) PS1644 1 TransformerAsm

05/15/89 PAGE 18 LIT 6422.18

Asm.

Page 20: CB, CC, CG Service Manual - 6422

PARTS IDENTIFICATIONContinued

KIT CONTENTPHOTOREF

NUMBERPARTS DESCRIPTION ORDER

NUMBER QTY DESC.

26 Circuit Board, Power

(CVAP-D, P.04)

PS1639 1 Power BoardAsm.

27 Wire Connector, Small (CB/CG) PS1533/6 6 Wire

ConnectorS

28 Cordset PS1595 1 Cordset

29 Circuit Board, Main PS1649 1 Control Board

& Housing

30 Buzzer PS1586 1 Buzzer

31 Switch, Push Button PS1100 1 Switch &Shield

32 Wiring Control PCCVAP (.03, .04) PS1673 1 Wire

Harness

33 Needle Valve Seat PS1418/6 6 Needle Valve

Seats

34 Inlet Tube & Connector (CVAP) PS1419 1

2

2

1

Water Line

Ferrules

Inserts

O-Ring

35 Float (Plastic Bulb Only) PS1657 1

1

Float Bulb

Screw

36 Thermocouple - Air (CVAP-D, P.04) PS1643 1

1

1

Probe, Air

Clamp

O-Ring

05/15/89 PAGE 19 LIT 6422.19

Page 21: CB, CC, CG Service Manual - 6422

CVAPVAPOR OVEN

COMPLETE UNIT(MODEL CG15P SHOWN)

05/15/89 PAGE 20 LIT 6422.20

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CVAPVAPOR OVEN AIR HEATERS, SHELF RACKS & FLOAT

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CVAPVAPOR OVEN

WATER HEATER

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CVAPVAPOR OVEN CONTROL PANEL

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CVAPVAPOR OVEN FLOAT SYSTEM/AIR THERMOCOUPLE

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Float Cover(Refrence Only)

35

33

34

36

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I

CVAPVAPOR OVEN SCHEMATIC (653P79)

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. . .

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TROUBLESHOOTING

SYMPTOMS FAULTS

No Power Light……………………………………………………1,2,3,4,33

Food drying out ……………………………………………... 5,7,10,12,23,28,32

Food excessively moist……………………………………………...8,9,11,27,28

Food not hot enough.……………………………………………...8,10,11 ,12,13,14,28

Food too hot……………………………………………...………………7,9,15,28

No heat (air or water) …………………...…….....……...………………15, 16,29

No heat (air) ……………………………………………...…...11 ,13,15,16,29,31

No heat (water) ...……………...………………………………..12,14,15,16,29,32

No display……………………...……………………………………………...16,29

Display sporratic. …………………...…………………………………...……..16,19

Unable to change channels.…...………………………………………16,17, 18, 20

LED(s) on channel indicator out. ..……………………………………………...16,20

Unit will not cook utilizing probe. …………………………………………...16,25

Unit will not go into Start (cook) mode. …………………………...……..16,30

Leaking water; flooding. ……………………………………………..6,21,22,24

Air heaters constantly on. ………………………………………………15, 16,26

Water heaters constantly on.………………….…………………………15,16,27

* For Display Error Messages (ER 1 thru ER 6), see EXPLANATION OF ERROR MESSAGES on page 28.

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TROUBLESHOOTINGFAUL TS

1. Cord set not plugged in.2. Circuit breaker tripped.3. Power Cord defective.4. Power Switch defective.5. Evaporator Tank empty.6. In-Line water tubing cut or kinked.7. Air temperature set too high.8. Air temperature set too low.9. Water temperature set too high.10. Water temperature set too low.11. Air heating element(s) defective.12. Water heating element(s) defective.13. Air heater terminal connection(s) loose.14. Water heater terminal connection(s) loose.15. Power Board defective.16. Control Board defective.17. Key Pad defective.18. Key Pad Strip defective.19. Control Board grounding wire loose or off.20. LED(s) defective.21. Float needs adjustment.22. Needle Valve Seat defective.23. Water-Inlet tube clogged.24. Drip Cup 0-Ring defective.25. Probe defective.26. Air Thermocouple defective.27. Water Thermocouple defective.28. Control Board out of calibration. Send in for repair.29. Transformer defective.30. Start Switch defective.31. Air Heater terminal connection on power board loose or off.32. Water Heater terminal connection on power board loose or off.33. Power Light defective.

EXPLANATION OF ERROR MESSAGESER 1. THROUGH ER 6

ERROR MESSAGE ER 1: Check air thermocouple #1 connection at the circuit board. Ifconnection is satisfactory, replace faulty termocouple.

ERROR MESSAGE ER 2: Check air thermocouple #2 connection at the circuit board. Ifconnection is satisfactory, replace faulty thermocouple.

ERROR MESSAGE ER 3: Check water thermocouple #3 connection at the circuit board.If connection is satisfactory, replace faulty thermocouple.

ERROR MESSAGE ER 4: Check probe thermocouple #4 connection at the circuit board.If connection is satisfactory, replace faulty thermocouple.

ERROR MESSAGE ER 5: Replace circuit board.ERROR MESSAGE ER 6: Replace circuit board.

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ZAPZero Accidents Program

4272V089 rev3 12/23/03 (800) 234-5286 or (502) 495-5400 Fax (502) 495-5458 Winston IndustriesPrices subject to change without notice. www.winstonindustries.com 2345 Carton DriveF.O.B. Louisville, KY, USA All sales subject to Company’s Terms and Conditions Louisville, KY 40299

ZAP WARRANTY AGREEMENTThis warranty agreement applies to Commercial Equipment, Equipment Service Parts, and Safety Parts (collectively, "Products") manufactured byWinston Industries, LLC ("Winston") and its corporate predecessors and is extended to any purchaser, lessee or successor purchaser ("Purchaser").

NEW EQUIPMENTAny part of a new Steamer appliance except gaskets, hoses, lamps, power cords, and evaporators which proves to be defective in material orworkmanship within three (3) years from the date of manufacture, will be repaired or replaced (at Winston's option) free of charge.

Any part of a new appliance, other than Steamers, except gaskets, hoses, lamps, power cords, fryer baskets, glass panels, and evaporators whichproves to be defective in material or workmanship within one (1) year from the date of original installation or 15 months from the date ofmanufacture, whichever comes first, will be repaired or replaced (at Winston's option) free of charge.

REPLACEMENT PARTSAny appliance replacement part except gaskets, hoses, lamps, power cords, fryer baskets, glass panels, batteries, and evaporators which proves tobe defective in material or workmanship within ninety (90) days from the date of original installation will be repaired or replaced free of charge.

LABOR, TRAVEL, TRANSPORTATIONThe warranty for new equipment covers the repair or replacement (at Winston's option) of the defective part(s), delivery of the replacementpart(s), labor charges for the removal and installation of replacement part(s) for one (1) year from the start of the warranty period. This warrantyincludes travel time not to exceed two hours and mileage not to exceed 50 miles (100 miles round trip).

The warranty for replacement parts covers the repair or replacement (at Winston's option) of the defective part(s) and does not include any laborcharges for the removal and installation of any part(s), travel, transportation or other expenses incidental to the repair or replacement of part(s).

The warranty does not cover: gaskets, hoses, lamps, power cords, fryer baskets, glass panels, evaporators, software, corrosion of stainless steel,normal maintenance, lubrication, cleaning or descaling, programming or adjusting temperatures, calibration, tightening of fasteners or plumbingconnections, appliances with removed or altered identification tags, damage resulting from delivery of the appliance, customer mishandling orabuse, or no problem found.

THE USE OF POOR QUALITY WATER WILL VOID PRODUCT WARRANTIES. See Product Use and Care Manual for water qualityrecommendations.

PROPER INSTALLATION IS THE RESPONSIBILITY OF THE DEALER, PURCHASER, OWNER/USER, OR INSTALLINGCONTRACTOR, AND IS NOT COVERED BY THIS WARRANTY.

As a condition to the application of this warranty, Purchaser will operate, clean and maintain Products in accordance with use and careinstructions, warnings, manuals and any other notices and/or instructions from Winston which may be with or on Products or sent separately; willnotify Winston of resale, removal or retirement of Products; will notify Winston immediately of any accident or injury arising out of use ofProducts and cooperate with Winston in the investigation of any such accident or injury; will maintain registration with Winston of location andserial number of Products while in Purchaser's control and use; will require all personnel operating Products to become thoroughly familiar withuse and care instructions and all other notices and/or instructions before such personnel operate Products; will thoroughly train all personneloperating Products to follow all instructions contained on or in all Safety Labels and use and care instructions; will immediately affix SafetyLabels and put into use the use and care instructions; will immediately use, according to instructions, Safety Parts supplied by Winston; will installEquipment Service Parts in accordance with Winston's written instructions; will utilize only Winston manufactured replacement parts and make nochanges or alterations to Products, except as approved or instructed in writing by Winston; and will when requested by Winston, cooperate withWinston in the prevention of injuries from Purchaser's use of Products.

PURCHASER'S SOLE AND EXCLUSIVE REMEDY AGAINST WINSTON SHALL BE FOR THE REPAIR OR REPLACEMENT OFDEFECTIVE PARTS AS PROVIDED HEREIN. THE TOTAL LIABILITY OF WINSTON WITH RESPECT TO ITS PRODUCTS, WHETHERUNDER WARRANTY OR OTHERWISE, SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCTS AND THE LABOR ANDTRAVEL TO REPLACE THE PRODUCTS OR ANY PART THEREOF. WINSTON SHALL NOT BE LIABLE TO THE PURCHASER OROTHERS FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSS OF PROFITSRESULTING FROM ANY CAUSE WHATSOEVER, INCLUDING BUT NOT LIMITED TO, DEFECTIVE WORKMANSHIP, MATERIALSOR ANY ERROR OR OMISSION OF WINSTON.

WINSTON EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING ANY IMPLIEDWARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND ANY IMPLIED WARRANTY OF MERCHANTABILITY.

For warranty inquiries and customer specific warranties, call Winston Customer Service at 1-800-234-5286 or 502-495-5400.

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PARTS ORDERING INFORMATION

ALWAYS REFER TO THE MODEL NUMBER AND SERIAL NUMBER WHEN PLACING APARTS ORDER.

Use only genuine Winston Products replacement parts in your appliance. Refer to the partsidentification section of this manual to identify the part(s) needed.

PROCEDURES FOR REPLACING NEW COMPONENTS ARE INCLUDED IN THIS MANUAL ANDIN EACH COMPONENT REPAIR KIT. FOLLOW THOSE INSTRUCTIONS CAREFULLY.

To order parts or obtain other information, contact:

WINSTON PRODUCTS COMPANY2345 Carton Drive

Louisville, Kentucky 40299(502) 491-1810

Customer Service (800) 234-5286

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